Re: KTM 200 Duke

There is no set number of km between adjustments. Check the slack every 1000km and adjust if required (which in most cases is not required if the chain is cleaned/lubed every 700km). A slightly loose chain is fine, but make sure the slack isn't too less (which a lot of mechanics tend to do). And remember that once you sit on the bike the chain 'tightens' up due to the load.
In my case i rarely have to get the chain adjusted, which is mostly during a routine service once in 6 months. I am still on the stock chain+rear sprocket at 33k km.. the front sprocket alone was replaced at around 28k km (Pulsar 220 front sprocket).

Re: KTM 200 Duke

Thanks brother for the information..

Re: KTM 200 Duke

Went to a battery shop yesterday, they said the battery has become slightly weak.

Today morning I checked the battery voltage, it showed around 11.9V. Then started the bike and increased RPM to around 7000, then the voltage started slowly increasing and started fluctuating between 12.8V to 13.4V. It never crossed 13.4V.
And also today once during cranking the console switched off and showed some JG error code for a few seconds and the console came back on automatically and bike started like normal.

So what does this mean that I have to replace stator aswell along with the battery?

Re: KTM 200 Duke

Can you swap the battery with a good one from another bike and check the voltages again. That will let you know for sure if it's a battery issue or a stator coil issue (which will eventually kill a battery if not replaced).
Another way to check the stator coil is by measuring the resistance between its pins.. check the workshop manual for the procedure/values.

Re: KTM 200 Duke

Today evening the bike wasn't starting. Did a push start. Then during riding noticed that at speed of below 20kmph, the Speedo showed 0kmph. This issue has come for the first time.

Got the battery replaced and checked the voltage, it was 12.8V at 6500RPM. So stator will have to be replaced at the earliest.

And how do I check if the Regulator Rectifier is fine?
If the voltage at the Battery terminal after changing stator is around steady 14V then is the RR working properly?
And also is it possible that the RR is faulty and the stator is fine at present? Will check the resistance as you have advised.

And just now I realised that I forgot to check the Speedo at below 20kmph after changing the battery, but I guess it should be fine now with the new battery.

Re: KTM 200 Duke

Check your speedo; if the console behaves as normal after changing the battery, it's probably a low battery issue. After replacing the stator, the voltage at the terminals of the battery should be 13.5 to 15v, with the engine spinning around 5k RPM (the Duke 390 manual suggests the same) Nonetheless, the reading should't go beyond the specified voltage with the engine at that RPM. If the voltage exceeds the stated voltage, RR has to be replaced. A faulty RR always increases voltage reading at the battery ends and reduces the battery life dramatically. If the voltage remains the same, as the adage goes, all is well.

Keep your observations jotted.

Cheers!
VJ

Re: KTM 200 Duke

With a properly working stator coil and rr unit, the voltage reading at 5500rpm should be around 14.5 V on a healthy battery (healthy battery stand alone voltage will be 12.6~12.9V). In your case it clearly is not shooting up above the 12.8V value. The RR unit usually doesn't go bad that early, most cases it is the stator coil.. you can check the resistance values as i mentioned earlier.
In such situations it is always easier to swap the battery / rr unit to perform checks. Since you already put in a new battery, try to swap the RR unit from another bike just to be sure it isn't the culprit.
If you let the new battery drain completely a few times it will impact it's life.. so go asap and get the coil (or rr) replaced, whichever is faulty. Am pretty sure it will be the coil.

Re: KTM 200 Duke

Checked the Resistance at the stator output terminals, the manual suggested the value should be less than or equal to 1 Ohm, and I got around 2 Ohms. The reading may be a multimeter error also.

Then checked the terminals of the output cable of the rectifier (2 core cable) and found white colour paste deposited on the terminals. Cleaned them with cloth and reinserted the connectors.

Then rechecked the battery voltage and this time the battery voltage was slowly increasing at rate of approx 0.02V per second at 7000 RPM. I held the revs till the voltage reached 13.3V then released the throttle.

Shouldn't the voltage increase the moment the engine is revved?

Re: KTM 200 Duke

yes it should, it will shoot up almost instantly. looks like the coil is gone for a toss.
and remember, without starting the bike the voltage of a good battery will be 12.6~12.9 V, at 5500rpm it will be approx 14.5V

Re: KTM 200 Duke

Guys, going to ladakh this year.
Any particular things i need to service before going.
Like particular parts to check/change.

ODO is around 26000. 4 Services(Free and Paid) done over all.
Stock chain sprocket, not sure about throttle body cleaning, whether it is done or not (Will ask SVC).
Changed Engine Head gasket couple of times because of oil leak.

TIA.

Re: KTM 200 Duke

When the voltage is checked at the end of the terminals, the voltage should spike almost immediately as you twist the throttle and stay steady after a certain RPM, in this case 5000-5500 RPM. If you observe voltage increasing in increments, with the throttle open, your stator is toast. It's advisable to change the stator as soon as you can. A weak stator would put undue stress on the RR, which would in turn heat up and cause failure of the RR which is highly likely.

The top three to replace would be engine oil, coolant, and brake pads (considering the kays done) before you embark on your trip. Make sure, your wheel bearings both front and rear are in perfectly good shape. it's also advisable to carry a spare clutch cable, clutch lever and front brake lever and rear brake pedal. In case of a mishap, considering the fragile nature of these components, they can snap just like that even on a mild fall, be safe than sorry. Carry a can of engine oil of the grade used on the engine before the trip and a can of CHAIN LUBE.

On a thorough note, I'd suggest you inspect where your chain life markings are on the swingarm and take a wise decision. A chain that is on the end of life or is already on the end of life note can run out of breath riding on extreme conditions, so it's always advisable to chain kit along with the rear cush drive. Also, inspect clutch and throttle cables for right play and slack.

Cheers!
VJ

Re: KTM 200 Duke

Guys, I'm thinking of changing the headlight and position lamp bulbs to white light bulbs. Which bulbs do you recommend?

Re: KTM 200 Duke

In short, they give you good throw, but fade under yellow light, i.e. street lights. White lights are also reduce stress on eyes compared to yellow halogens, and improve visibility. You can try Philips, Osram and those Chinese LEDs, they consume less power and offer more or less the same performance, wattage wise and offer decent life.

Cheers!
VJ

KTM DUKE 200 not firing UP

hi there, its my first help post in XBHP family, i own a 2013 KTM duke 200. ridden around 18000 KM with a factory packed engine. i recently got its fuel pump changed due to the lack of power of the bike. after a day, i started to notice that the bike was automatically killing its RPM once i pass any obstacle on road IE. a speed breaker, next day, when i tried to fire up the engine. nothing happened. every digital part of my bike is working fine supposed to be, except engine itself, when am hitting the self switch, motor is doing its work but there is no movement in bike. i doubt that its the issue of roll over switch (tip over switch). because the day before i changed its fuel pump, bike was fallen down, and it didn't turned off itself until i didn't turned it off. can anyone guide me the location of roll over switch in my 2013 duke 200 ? and is it possible to start the bike after removing a roll over switch ?
also, when i am turning on my bike, i am getting engine light error (1 time long, followed by 6 short blinks)

Re: KTM DUKE 200 not firing UP

better get it checked at the svc with their diag too, it will pin point the cause of the malfunction.
from the rc 390 manual, i came across these:

1 - 5 roll over sensor
1 - 6 radiator fan motor
6 short - throttle position sensor related
1 - 7 is lambda sensor related
1- 8 is engine diagnosis warning